Blackout Material

ABSTRACT

A blackout material is provided and includes a woven fabric including a weft set and a warp set, the weft set being black. More than 50% of a first surface of the woven fabric comprises the warp set. The blackout material further comprises a light excluding coating on the outer surface of the woven fabric, the light excluding coating including at least one black layer. A method of making a blackout material is provided and includes weaving a woven fabric including a weft set and a warp set, the weft set being black. More than 50% of a first surface of the woven fabric comprises the warp set. The method further comprises applying a light excluding coating on the outer surface of the woven fabric.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of U.S. patent application Ser. No. 15/711,543 filed Sep. 21, 2017 (pending), the disclosure of which is incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates generally to blackout material and to methods of making same.

BACKGROUND OF THE INVENTION

Conventional draperies are primarily designed for style and appearance and are generally made from premium fabrics of various colors and designs. However, such fabrics are generally ineffective for preventing a substantial quantity of light from penetrating into a room. Blackout draperies and drapery linings are typically used by hotels and motels in order to ensure that guest rooms can be maintained substantially dark at all times of the day. Blackout draperies are also used residentially where the amount of light penetration into a bedroom at night may be considerable due to sources such as street lights, light from adjacent buildings, and automobile headlights. Blackout draperies or drapery linings are generally made of a woven textile substrate. The substrate is also coated with one or more layers of an acrylic latex based compound or foam, treated with resins such as water repellent, with an adhesive compound, or with fire-retardant materials, or with selected combinations. For many applications, it is essential that the blackout draperies or drapery linings are flame retardant. Flame retardancy is usually achieved by application of a suitable coating.

However, conventional blackout fabrics present numerous disadvantages. For example, blackout fabrics are often bulky and stiff due to their manufacture. Additionally, such blackout fabrics drape poorly and have a high cost of production. Further, to provide a blackout fabric without pin holes through which light passes, the material must be of a plain, flat weave. This limits the amount of design and texture of the face fabric.

Therefore, there is a need for an improved blackout material that addresses these problems.

SUMMARY OF THE INVENTION

One objective of the present invention is to provide an effective blackout material for preventing a desired amount of light from passing through the material. Other objectives are to reduce the costs of making such material and to provide a woven textured material with surface interest.

According to one embodiment of the present invention, a blackout material comprises a woven fabric including a weft set including a plurality of black weft yarns and a warp set including a plurality of warp yarns. The woven fabric has a first surface and a second surface, and more than 50% of the first surface comprises the warp set.

According to one embodiment of the present invention, a method of making a blackout material comprises weaving a woven fabric including a weft set and a warp set, the weft set being black, the woven fabric including a first surface and a second surface. More than 50% of the first surface comprises the warp set.

These and other objects and advantages of the present invention will be apparent from the following detailed description of the embodiments which are illustrated in the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a front view of a woven fabric according to an embodiment of the present invention.

FIG. 2A illustrates a cross-sectional view of the woven fabric taken along the line 2A-2A of FIG. 1.

FIG. 2B illustrates a cross-sectional view of the woven fabric taken along the line 2B-2B of FIG. 1.

FIG. 3 is an interlacing diagram showing a face surface of the woven fabric of FIG. 1.

FIG. 4 is a cross-sectional view of a coated blackout material according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to the drawings, and particularly FIGS. 1-4, a blackout material 10 is illustrated according to an embodiment of the present invention. The blackout material 10 includes a woven fabric 12 that includes a weft set 14 and a warp set 16. The weft set 14 includes a plurality of weft yarns used in weaving that are oriented in the cross machine direction of the weaving loom. The weft set 14 includes black weft yarns that create light exclusion properties. The warp set 16 includes a plurality of warp yarns used in weaving that are oriented in the machine direction of the weaving loom. The weft yarns are at a right angle relative to the warp yarns.

With reference to FIGS. 1-3, the set of warp yarns 16 are selectively interlaced with the set of weft yarns 14 using a weaving system such that the woven fabric 12 is warp-faced. In other words, the set of warp yarns 16 are selectively interlaced with the set of weft yarns 14 such that a face surface 18 is predominantly composed of the set of warp yarns 16 and a back surface 20 is predominantly composed of the set of weft yarns 14. In various embodiments, the weft set 14 may form more than 50%, more than 60%, more than 70%, more than 80% of the back surface 20. The woven fabric 12 includes long, floating black yarns and is tightly paralleled. The yarn characteristics and weave structure may create a smooth back surface 20 for improved coating adherence and blackout quality.

Still referring to FIGS. 1-3, in an embodiment, a weaving system includes a repeating pattern 22 that is 5 weft yarns by 5 warp yarns. The set of warp yarns 16 may be selectively interlaced with the set of weft yarns 14 such that a first warp yarn 16 a may float over four weft yarns before passing under a first weft yarn 14 a. Second and third warp yarns 16 b, 16 c also float over four weft yarns before passing under second and third weft yarns 14 b, 14 c. The second warp yarn 16 b is adjacent to the first warp yarn 16 a, and the second weft yarn 14 b is separated by two weft yarns from the first weft yarn 14 a. The third warp yarn 16 c is adjacent to the second warp yarn 16 b, and the third weft yarn 14 c is adjacent to the first weft yarn 14 a.

The characteristics of the weft and warp yarns may vary. For example, the size of the weft yarn may be, without limitation, 50D, 75D, 100D, 150D, 200D, 250D, 300D, and 450D. For example, the warp yarn sizes may include, without limitation, 50D, 75D, 100D, 150D, 200D, 250D, 300D, 450D, and 600D. Further, the warp yarn may be dyed or printed. The fiber material or blend of the weft and warp yarns may vary. The weft and/or warp yarn may be made of, without limitation, polyester, cotton, linen, rayon, viscose, bamboo, nylon, polyamide, polypropylene, or a combination thereof. The weft and/or warp yarn may be traditional yarn, flame retardant (FR) treated yarn, or inherently flame retardant (IFR) yarn (e.g., polyester).

The blackout material 10 may be constructed in different configurations of warp and weft yarn and weaving techniques. For example, the appearance of the weave may be, without limitation, plain, box, dobby, jacquard, satin, knit, linen, brushed, textured, etc. Further, the number of yarns per inch in each of the weft set 14 and the warp set 16 may vary with the desired fabric appearance. Although only one weft set 14 and one warp set 16 is shown, the blackout material 10 may include one or two weft sets 14 and one or two warp sets 16 depending on desired surface appearances. Further, to achieve a variety of decorative fabric surfaces, the blackout material 10 may be woven with texture patterns or with use of warp yarn characteristics such as slub yarn, flat yarn, brushed yarn, yarns of varied thickness or texture, and various fiber blends. The blackout material 10 may be used in draperies, drapery linings, or roller shade products.

With reference to FIG. 4, in an embodiment, the blackout material 10 is constructed with the woven fabric 12 and a light excluding coating 24 on the surface 20 of the woven fabric 12. The light excluding coating 24 includes a first coating layer 26 and a second coating layer 28. The colors of the coating layers 26, 28 may vary. For example, in an embodiment, the first coating layer 26 is black. In an embodiment, the second coating layer 28 is white or another light color, such as ivory, ecru, etc. Further, it should be recognized that the coating layers 26, 28 may have other colors depending on the desired appearance of the blackout material 10. One or more layers 26, 28 of the light excluding coating 24 may optionally be flame retardant (FR). In addition to the color, the composition of the layers 26, 28 may differ. The material for the light excluding coating 24 may include, without limitation, one or more of acrylic, titanium dioxide, flame retardant agents, such as decabromodiphenyl ethane (DBDPE) and antimony (III) oxide, and other compound agents. Further, the material for the light excluding coating 24 may be foam. Although two coating layers are shown, it should be recognized that the light excluding coating 24 may include only one layer (e.g., for use in residential applications) or more than two layers (e.g., three, four, etc.). Each coating layer may have a weight of from 35 to 90 gsm. For example, an initial coating layer (not shown) may be applied to the woven fabric 12 before the black coating layer 26. The blackout material 10 may have a reduced basis weight and thinner profile compared to conventional blackout material, which creates an aesthetically attractive product.

With further reference to FIG. 4, the light excluding coating 24 may optionally be flocked. For example, a flock layer 30 may be electrostatically applied to an outer surface 32 of the light excluding coating 24. The flock layer 30 may be made of, for example, Rayon, polyester, cotton. The flock layer 30 may be applied using other techniques and materials known in the art.

Still referring to FIG. 4, additional coatings 34 may be applied to the woven fabric 12. In the illustrated embodiment, the additional coatings 34 are applied to the face surface 18 of the woven fabric 12. Alternatively, the additional coatings 34 may be applied to both surfaces 18, 20 of the woven fabric 12. For example, the woven fabric 12 may be immersed in a coating material. The additional coatings may include, without limitation, a water repellant treatment, soil and stain resistance treatments, antimicrobial treatment, etc. In an embodiment, a water repellant agent may be applied and cured before the application of the light excluding coating 24. A suitable water repellant agent may include silicon. For example, the coating 34 may include a fabric softener, which provides a water repellant finish. In another embodiment, some applications of the blackout material 10 may require a topical FR treatment prior to applying the light excluding coating 24 in order to meet fire or safety codes.

A method of making the blackout material 10 is now described. The woven fabric 12 is woven using, for example, black weft yarn and white warp yarn. The woven fabric 12 may be constructed on typical water jet, air jet, rapier loom, or projectile loom for example. The woven fabric 12 may optionally be prepared for application of the light excluding coating 24 by applying a water repelling agent 34 to woven fabric 12. For example, a water repelling agent 34 may be topically applied to both surfaces 18, 20 of the woven fabric 12. Depending on the material, the additional coatings 34 may be cured. A first, black coating layer 26 is applied to the surface 20 of the woven fabric 12, followed by application of the second, white coating layer 28. During the application of the second coating layer 28, the blackout material 10 is exposed to a calendar operation and curing process to bind the coating layers 26, 28 together. The crushing effect of the calendar and the heat and dwell time in a finishing frame result in the binding of the woven fabric 12 to the light excluding coating 24 and the adhering of all coating layers 26, 28 together (i.e., the binding agents in the light excluding coating 24 are chemically cross-linked).

Although only certain exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that various modifications can be made without departing from the principles of the present invention. Accordingly, all such modifications are intended to be included within the scope of this invention. 

What is claimed is:
 1. A blackout material comprising: a woven fabric including a weft set including a plurality of black weft yarns and a warp set including a plurality of warp yarns, the woven fabric having a first surface and a second surface; and a light excluding coating on the second surface of the woven fabric, the light excluding coating including at least one black layer, wherein more than 50% of the second surface comprises the weft set.
 2. The material of claim 1, wherein more than 80% of the second surface comprises the weft set.
 3. The material of claim 1, wherein each of the warp yarns floats over four weft yarns before passing under one of the weft yarns.
 4. The material of claim 1, wherein at least one of the weft set or the warp set are flame retardant treated or inherently flame retardant.
 5. The material of claim 4, wherein at least one of the weft set or the warp set are made of polyester.
 6. The material of claim 1, wherein each pair of adjacent warp yarns passes under only non-adjacent weft yarns.
 7. The material of claim 1, wherein the light excluding coating includes at least one additional layer.
 8. The material of claim 1, wherein the light excluding coating is flame retardant.
 9. The material of claim 8, wherein the light excluding coating comprises acrylic.
 10. The material of claim 1, further comprising: a flock layer on an outer surface of the light excluding coating.
 11. The material of claim 1, further comprising: a water repellant agent on the second surface of the woven fabric.
 12. The material of claim 1, further comprising: a topical flame retardant agent on the second surface of the woven fabric.
 13. A method of making a blackout material comprising: weaving a woven fabric including a weft set and a warp set, the weft set being black, the woven fabric including a first surface and a second surface; applying a light excluding coating on the second surface of the woven fabric; and binding the light excluding coating to the woven fabric, wherein more than 50% of the second surface comprises the weft set.
 14. The method of claim 13, wherein weaving includes floating each of the warp yarns over four weft yarns before passing under one of the weft yarns.
 15. The method of claim 13, wherein applying a light excluding coating comprises applying a first black coating layer and applying a second coating layer.
 16. The method of claim 13, wherein binding includes exposing the woven fabric and light excluding coating to a calendar operation.
 17. The method of claim 13, further comprising: applying a flock layer to an outer surface of the light excluding coating.
 18. The method of claim 17, wherein the flock layer is electrostatically applied to the outer surface of the light excluding coating.
 19. The method of claim 13, further comprising: applying a water repellant agent to the woven fabric before applying the light excluding coating.
 20. The method of claim 13, further comprising: applying a topical flame retardant agent to the woven fabric before applying the light excluding coating. 